Electric motor driven loader with electric motor powered hydraulics

ABSTRACT

An electric loader is provided with a plurality of independently driven wheels. For example, a four-wheeled electric loader includes four independently operated wheels, each directly coupled to a dedicated electric motor. A fifth independent electrical motor powers the lift arm and/or any attachments coupled to an auxiliary hydraulic. A central forced-air system supplies pressurized air to each independent electric motor to cool the electric motor during operation. In some embodiments, the auxiliary electric motor powers the fan and/or air conditioner of the central forced-air system. A lever and/or electric brake may be applied to an axle of the electric motors. In some embodiments, a rotating or pivotable battery panel locks a plurality of battery cells to provide a central source of power, counter-weight the loader arm, and rotate away to provide the operator access to an internal cavity of the cab.

CROSS-REFERENCE TO RELATED PATENT APPLICATION

The present application claims the benefit of and priority to U.S. Patent application No. 62/986,481 filed on Mar. 6, 2020, which is incorporated herein by reference in its entirety.

BACKGROUND OF THE INVENTION

The present invention relates generally to the field of battery powered vehicle loaders such as skid steer and tracked loaders, which include electric motors to drive wheels of the loader and at least one electric motor to drive the hydraulic loader cylinders and auxiliary power hydraulics of the loader.

SUMMARY OF THE INVENTION

One embodiment of the invention relates to an electric (e.g., battery powered) skid steer loader with an independent drive at each wheel. The electric loader has a first electric motor having a gear reducer and directly coupled to a first external drive and a second electric motor having a gear reducer and directly coupled to a second external drive. A third electric motor, or auxiliary electric motor, is coupled to a loader. In various embodiments, the external drives are wheels or tracks and are driven independently.

Another embodiment of the invention relates to an electric loader skid steer or tracked loader with a battery pack door for storing power cells. The electric loader has a first and second electric motor, each having a stator, a rotor, coil windings, and an axle coupled to a planetary gear system coupled to a rotary hub. The battery panel is pivotably coupled to a frame of the electric loader and is electrically coupled to the first and second electric motors. The battery panel rotates from an upright locked position to a lowered unlocked position.

Another embodiment of the invention relates to a forced-air cooling system for an electric motor on an electric loader. The electrically powered loader has a plurality of electric motors and a forced-air system. Each electric motor has a cover, a rotor, a stator, a coil winding, and a gap. The cover at least partially surrounds the electric motor and has an input port. The rotor is coupled to an axle that rotates in the presence of an electromagnetic field. The stator generates the electromagnetic field when an electric current is passed through the stator. The coil winding is located on at least one of the rotor and the stator and has at least one gap. The forced-air system includes a filter, a fan, and a plurality of ducts. The filter cleans the air entering the forced-air system and removes particles and humidity. The fan forces air through the forced-air system. The ducts lead the forced-air to each electric motor. The ducts are coupled to the input port of the cover at each electric motor.

Another embodiment of the invention relates to retrofitting a conventional unit with an electronic motor and battery system.

In various embodiments of the invention, a lever brake is used to provide a compressive force on an axle that is coupled to the rotor of one of the electric motors to lock the shaft or axle and apply a parking brake the electric loader.

Alternative exemplary embodiments relate to other features and combinations of features as may be generally recited in the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

This application will become more fully understood from the following detailed description, taken in conjunction with the accompanying figures, wherein like reference numerals refer to like elements in which:

FIG. 1 is a side perspective view of an electric loader with four (4) driven wheels and the loading bucket removed, according to an exemplary embodiment.

FIG. 2 is a side perspective view of an electric loader of the type shown in FIG. 1 , with the bucket attached.

FIG. 3 is a front perspective view of the electric loader of FIG. 1 ;

FIG. 4 is a back perspective view of the electric loader of FIG. 1 showing an open back panel door, according to an exemplary embodiment.

FIG. 5 is a side perspective view of an electric loader driven by tracks, according to an exemplary embodiment.

FIG. 6 includes view of an electric wheel assembly configured to receive an electric motor, according to an exemplary embodiment.

FIG. 7 is a top view of the electric wheel assembly of FIG. 6 showing an installed motor coupled to an independently driven wheel, according to an exemplary embodiment.

FIG. 8 is a hub that includes a wheel end gear drive, according to an exemplary embodiment.

FIG. 9 is an electric motor showing a rotor, a stator, windings, and gaps, according to an exemplary embodiment.

FIG. 10 is an electric motor-hub assembly showing a filter for forced-air venting, according to an exemplary embodiment.

FIG. 11 is a fixed hub connection for attaching the wheel end gear drive of FIG. 8 to a body of the electric loader, according to an exemplary embodiment.

FIG. 12 is an electric loader with four independent motor assemblies (un-installed) for independently driving tracks or wheels at each electric motor-hub assembly, according to an exemplary embodiment.

FIG. 13 is a side view of a gear drive for powering a hub of a track or wheel, according to an exemplary embodiment.

FIG. 14 is a side view of an electric loader that includes a port for receiving the electric motor-hub assembly of FIG. 8 and a control port to facilitate the connection of wiring to an associated electric drive motor.

FIG. 15 is a view of an electric motor-hub assembly being coupled to the port of an electric loader.

FIG. 16 follows the installation of FIG. 15 to show how the fixed hub is attached to a side of the electric loader to support the installed electric motor-hub assembly.

FIG. 17 is a side view of an electric loader with front and rear electric motor-hub assemblies installed and a central control port for connecting each electric motor to a central processor and/or power source or battery pack, according to an exemplary embodiment.

FIG. 18 is an isolated perspective view of a graphical user interface for an operator to interface with a processor and/or control panel, according to an exemplary embodiment.

FIG. 19 shows the graphical user interface of FIG. 18 inside a cab of an electric loader, according to an exemplary embodiment.

FIG. 20 is an electric loader including four electric motor-hub assemblies to independently drive four-wheel locations, according to an exemplary embodiment.

FIG. 21 shows the electric loader of FIG. 20 with four wheels installed at each electric motor-hub assembly.

FIG. 22 is an electric motor hydraulic pump assembly to power the hydraulic lift system and one or more hydraulic auxiliary units, according to an exemplary embodiment.

FIG. 23 is a front perspective view of the electric motor hydraulic pump assembly shown in FIG. 22 .

FIG. 24 is a cross-sectional view of an electric motor, including a housing configured to vent forced-air through the electric motor and cool the assembly, according to an exemplary embodiment.

FIG. 25 is a top perspective view of a central forced-air system including an electric motor coupled to a squirrel fan that forces air through a plurality of ducts to each electric motor-hub assembly, according to an exemplary embodiment.

FIG. 26 is a side perspective view of the central forced-air system of FIG. 25 .

FIG. 27 is a bottom perspective view of the central forced-air system of FIG. 25 .

FIG. 28 is a side perspective view of the central forced-air system of FIG. 25 .

FIG. 29 is a top perspective view of a central forced-air system including an electric motor coupled to a fan that forces air through a plurality of ducts to each electric motor-hub assembly, according to an exemplary embodiment.

FIG. 30 is a bottom perspective view of the central forced-air system of FIG. 29

FIG. 31 is a top perspective view of FIG. 29 .

FIG. 32 is a side perspective view of FIG. 29 with a chain-case removed.

FIG. 33 is a side perspective view of FIG. 29 with the chain-case installed.

FIG. 34 is a view of the cooling duct coupled to the electric motor of FIG. 24 and configured to force air through coils of the electric motor, according to an exemplary embodiment.

FIG. 35 shows porting holes for venting the electric motor, according to an exemplary embodiment.

FIG. 36 is a squirrel fan for forced-air venting of electric motors, according to an exemplary embodiment.

FIG. 37 is a perspective back view of a battery panel accessed by opening a backdoor of the electric loader, according to an exemplary embodiment.

FIG. 38 is a perspective back view of the battery panel of FIG. 37 , wherein the battery panel has been rotated to provide access to an internal cavity of a cab, according to an exemplary embodiment.

FIG. 39 is a top view of the backside of the battery panel shown in FIG. 38 to show the wires interconnecting the batteries to provide power to each electric motor assembly, according to an exemplary embodiment.

FIG. 40 shows a motor controller coupled to an electric motor that controls and/or regulates the electric energy delivered to the electric motor, according to an exemplary embodiment.

FIG. 41 is an isometric back view of the electric loader that shows the battery panel in an upright position and the open backdoor, according to an exemplary embodiment.

FIG. 42 is an isometric back view of FIG. 41 wherein the battery panel is rotated into a lowered position to provide access to the internal cavity of the cab.

FIG. 43 is a top isometric view of the electric loader FIG. 41 showing the open backdoor.

FIG. 44 is a top isometric view of the electric loader of FIG. 42 showing the battery panel rotated into a lowered position to provide access to the internal cavity of the cab.

FIG. 45 is a top isometric view of the electric loader with a closed backdoor and the installed battery panel in an upright position to provide a counterweight to the front end of the loader, according to an exemplary embodiment.

FIG. 46 is an isolated view of a rotating battery panel, according to an exemplary embodiment.

FIG. 47 is a top side perspective view of an isolated rotating battery panel showing in the upright or locked position.

FIG. 48 is a top side perspective view of an isolated rotated battery panel shown in the lower or open position.

FIG. 49 is an isometric view of a backside of the battery panel inside the isolated frame and in a locked upright position.

FIG. 50 is an isolated view of the battery panel showing various control knobs and ports to charge individual battery cells and/or remove battery cells.

FIG. 51 is an isolated view of the battery panel from an inside of the cab, showing a variety of storing locations for a plurality of battery cells.

FIG. 52 is a side perspective view of the rotated battery panel in an unlocked position to provide access to an internal cavity of the frame.

FIG. 53 is a side perspective view of an empty battery panel in the locked upright position, without any installed battery cells.

FIG. 54 is a side perspective view of the battery panel of FIG. 53 with installed battery cells.

FIG. 55 is a side perspective view of an empty battery tray.

FIG. 56 shows a battery cell and a battery box that is secured into a battery panel of FIG. 55 .

FIG. 57 is a side perspective view of an empty battery tray.

FIG. 58 is a front perspective view of the battery pack in a rotated or unlocked position within the frame.

FIG. 59 is a front perspective view of the battery pack in an upright or locked position within the frame.

FIG. 60 is an isometric front view of the battery pack showing in FIG. 59 .

DETAILED DESCRIPTION

Referring generally to the figures, an electrically powered skid steer or lift/loader is shown that uses a control system and four independent electric motors to achieve a variety of different steering and/or traction control modes. The electric lift loader includes four independent drive motors coupled to each wheel (or track) that controls traction and powers each wheel independently. For example, each wheel has its own independently controlled electric motor that is coupled to the wheel through a gear box (e.g., a planetary reducing gear system). Conventional skid steers include a chain drive that ties both of the wheels on a side of the unit together. In contrast, the electric skid steer independently controls and maps a variety of different steering, drive, and traction modes by independently controlling each of the four wheels with a processor and/or controller. This configuration provides 1, 2, 3, or 4 wheel drive based on user input and/or selection and enables, for example, powering only the rear wheels for efficiency when traction is not scarce or when the loader elevates the front wheels. In addition, steering can power different sets of wheels than forward and rearward directions. For example, one front wheel and one rear wheel could be driven (powered) independently to reduce slipping on turf to reduce turf damage.

In another embodiment, a battery panel or pack is assembled in a vertical direction to store battery cells, e.g., 12 or more. A pivoting battery box is installed into a frame of the electric loader to pivot the entire battery panel down (e.g., horizontally). Pivoting the battery box down (horizontally) permits an operator unfettered access to an internal cavity of the cab at the rear of the electric loader. In addition, the vertical orientation of the locked and operational battery panel increases the counter-weighting (ballast) of the lifting loader to offset any load applied, e.g., to a loading bucket or lift arm.

Applicant has found that these advantages result in reduced damage to the ground (e.g., turf) and improved tire performance/lifecycle through reduction in skidding and dragging on asphalt, turn, mud, etc. Additional maneuverability is also available, since each electric motor can be independently powered, a user can change or alter the center point of rotation of the machine based on the type/mode of steering. Traction is also improved when the system independently monitors each wheel for slip. Applicant has found that the efficiency of the electric loader is enhanced by delivering powers only to wheels on demand, such that power is consolidated and only used at the times and locations it is needed, to improve the efficiency and battery life of the electric loader system. Similar electric motors drive conventional hydraulic systems to control lift arms, accessories, and other attachments.

FIGS. 1 and 2 are side perspective views of an electric loader 10. FIGS. 3 and 4 are front and back perspective views of electric loader 10. As shown in FIGS. 1-5 , electric loader 10 has an external drive such as tracks 12 (FIG. 5 ) or wheels 14 that can be individually powered by an electric motor 16. In some embodiments, a plurality of electric motors 16 may be coupled or chained to operate in the same function, for example, two electric motors 16 turn at equal RPM to drive a track 12. In other embodiments, each electric motor 16 is driven independently. In this configuration, electric loader 10 can use a central processor to control each wheel 14. In some embodiments, a back access or backdoor 20 protects a power supply or battery panel 22 housing individual battery cells 24. Placing battery panel 22 in a rear part of electric loader 10 serves as a counterweight or ballast for a loading arm or loader arm 26 and/or bucket used to lift and/or move a load.

In some embodiments, the processor is coupled to each electric motor 16 and/or wheel 14 independently to enhance the operation and efficiency of electric loader 10 and/or reduce slip. For example, the processor allows an operator to select from a variety of drive modes. Each drive mode is selected independent of wheel 14 and/or tread 28. Specifically, an operator selects from traction control drive modes; such as rock, four-wheel, locked front or rear differential, snow, lawn, concrete, low tire wear, speed, and/or slope. User selection of appropriate drive modes enhances the user experience. For example, a drive mode that reduces slip on a lawn prevents wheels 14 from spinning and tearing up grass in the environment.

Similarly, independent control of each wheel 14 enhances electric loader 10 operation in snow, mud, ice, and other slip environments. The processor may be used to manually control electric motor 16 on each wheel 14 to reduce slip and improve traction in these environments. For example, electric loader 10 has lower tire wear to prolong tread 28 or may have a concrete mode for efficient non-slip operation on level paved surfaces.

The processor may include various sensors 30 to detect slipping at each wheel 14. In some embodiments, when signals from sensor 30 detect slipping the processor can reduce power to an affected wheel 14 (e.g., independently of the power delivered to other wheels 14) to reduce and/or eliminate the slip. Similar learning processes may be used to program the processor. For example, repeated passes over a sloped environment traditionally require an operator to countersteer against the slope to drive in a straight line. Similarly, wind, and unbalanced load, and/or other environmental effects may require an operator to countersteer to drive a conventional loader. In some embodiments, sensors 30 can detect wind, unbalanced loads, and/or slope changes while operating electric loader 10 and compensate the power delivered to each wheel 14 to reduce or eliminate the required operator input. In other words, an operator can drive straight (e.g., without any offset) along a base of a hill or other slope. Similarly, a load sensor 30 on a bucket of electric loader 10 can detect an unbalanced load, and the processor can automatically scale power to electric motors 16 coupled directed to each wheel 14 to offset and/or eliminate the environmental pressures. As noted above, in various embodiments, the processor can use sensors to automate control of each wheel 14 independently and/or receive user input to control traction of each wheel 14.

Electric loader 10 can be a skid steer, track skid, telehandler, lift, forklift, or another loader with lift or loader arm 26. In some embodiments, electric loader 10 has two tracks 12 each driven independently by one or more electric motors 16. In other embodiments, electric loader 10 has an electric motor 16 for each wheel 14, for example, four electric motors 16 drive four wheels 14 independently. In some embodiments, an additional or auxiliary electrical motor 16 a powers a hydraulic lift and/or auxiliary units coupled to a hydraulic or mechanical accessory unit. In some embodiments, an auxiliary attachment connects directly to auxiliary electric motor 16 a. As shown in FIG. 5 , in some embodiments, electric loader 10 is driven by tracks 12.

FIG. 6 shows an electric wheel assembly 32 that has a wheel 14 with a tread 28, a fixed hub 34, an electric motor 16, a gear reducer 36, and an internal or rotating hub 38 of wheel 14. In a preferred embodiment, gear reducer 36 is an elliptical or planetary gear set wheel end. In this preferred embodiment, such a wheel end would have a torque multiplier in the range of 60 to 100, but the torque multiplier would be selected based upon motor torque and power, desired loader speed range, and desired loader tractive effort.

Electric wheel assembly 32 receives electric motor 16 within wheel 14. In other words, electric wheel assembly 32 includes a motor 16 directly coupled to a gear reducer 36 directly coupled to a wheel 14. In this configuration, electric wheel assembly 32 is individually controlled (e.g., by a central processor) to independently control the rotation of each wheel 14 on electric loader 10. As described above, individual control of electric motors 16 improves traction at each wheel 14. Additionally, the system enhances operator control of traction modes, e.g., automatically through a feedback loop between sensor 30, local controller 40, the central processor, and electric motor 16 and/or through operator inputs related to the working environment. In some embodiments, local controller 40 is the central processor.

In various embodiments, gear reducer 36 replaces a conventional chain-case 42 to transform the output of electric motor 16 to control the torque and/or speed at wheel 14. For example, gear reducer 36 is a planetary gear reduction inside a rotating hub 38 of wheel 14. In various embodiments, gear reducer 36 may have between 150:1 to 40:1 torque reduction, specifically, between 110:1 to 50:1, specifically between 100:1 and 60:1 and, more specifically, between 80:1 and 60:1. In various embodiments, each battery cell supplies a 48V to 72V potential charge and is recharged with a 120V to 220V charge. For example, a 48V potential with 100 A current at each wheel 14 provides for a 4.8 kW of electric power for electric motor 16 at each wheel 14. In various embodiments, at least 4.0 kW of electric power for the electric motor 16 is provided for at each wheel 14, specifically, at least 6.0 kW, and more specifically at least 8.0 kW. In a specific embodiment, at least 10 kW of electric power is provided to each electric motor 16 independently coupled to each wheel 14.

Independent control of electric motors 16 at each wheel 14 enhances steering and other benefits. Specifically, independent control of wheels 14 enables side shifted wheels 14 on a forklift or other electric loader 10. In some embodiments, electric loader 10 is equipped with a 3-Dimensional or spherical drive wheel 14 to facilitate motion in any direction.

FIG. 7 is a top view of the electric wheel assembly 32, shown in FIG. 6 . As shown in FIG. 7 , electric motor 16 is installed within a cavity of exterior body 44 of electric loader 10 and directly couples to an independently driven wheel 14, such that electric motor 16 is the source of power that controls wheel 14. In other words, there is a 1:1 relationship between electric motor 16 and wheel 14 such that the processor controls each electric motor 16 to control the drive or rotation (e.g., RPM) of each wheel 14 on electric loader 10. FIG. 7 shows a motor housing or cover 46 that surrounds electric motor 16, and a duct 48. In some embodiments, duct 48 supplies forced-air to help cool electric coils on electric motor 16. In some embodiments, a rotor 50 further includes a cooling fan such that the forced-air is returned over the coils 52 on both stator 54 and/or rotor 50 to help maintain the temperature of the electric motor 16.

FIG. 8 is a hub that includes a wheel-end gear or drive gear reducer 36. FIG. 8 shows the hub assembly of FIG. 8 , coupled to an electric motor 16 to form an electric motor-hub assembly 56. FIG. 8 shows a cover 46 surrounding electric motor 16 for forced-air venting to cool coils 52 of electric motor 16 during operation. In various embodiments, cover 46 includes fins 58 to radiate off waste heat. With reference to FIG. 8 stationary or fixed hub 34 couples to a side body 44 of electric loader 10. Drive gear reducer 36 is coupled to an exterior of electric loader 10 and couples directly to a track 12 or wheel 14. In some embodiments, drive gear reducer 36 is a planetary gear reduction for electric motor to reduce the torque and increase the speed received from electric motor 16. For example, drive gear reducer 36 reduces the torque received from electric motor 16 to increase a speed of rotation (RPM) of wheel 14. In other embodiments, this process is reversed, such that an output speed of electric motor 16 is reduced by drive gear reducer 36 and the output torque at wheel 14 is increased. FIG. 8 shows openings in a top part of cover 46. For example, pressurized or forced-air is forced through the top of cover 46 and through electric coils of stator 54 and/or rotor 50 to cool electric motor 16. As shown in FIG. 8 , fixed hub 34 couples to a side of body 44 such that electric motor 16 is within body 44 and drive gear reducer 36 extends outside body 44. In some embodiments, the side of body 44 is recessed such that wheels 14 are at least partially covered or surrounded by a portion of body 44.

In some embodiments, electric motor 16 is located in a sealed environment, and heat is transferred from electric motor 16 to a base casting and/or cover 46. Cover 46 includes fins 58 for natural convection of the generated heat away from cover 46. A forced clean air cooling system 60 delivers pressurized clean and/or cool air through stator 54, rotor 50, and/or a gap 62 between stator 54 and/or rotor 50 to remove heat from coils 52 (e.g., copper windings), magnets 64, lamination steel, and/or iron of stator 54 and/or rotor 50. In some embodiments, rotor 50 includes ¾ inch diameter holes for circulating the forced-air. Spacing or gaps 62 between rotor 50, stator 54, and/or coils 52 enables the air to flow from a top of stator 54 to a bottom of stator 54. In various embodiments, gap 62 is between 0.01 inches and 0.09 inches wide, specifically, between 0.02 inches and 0.08 inches, and more specifically about 0.06+/−0.01 inches wide. In this configuration, forced clean cool air contacts magnets and/or a tip of stator teeth, where iron losses are generated. Forced-air escapes out of slots of base casting for supporting electric motor 16 and/or stator 54. For example, the escaping forced-air may be vented into a chain casing which is selectively vented to the interior of cab 66 (e.g., to warm the operator on a cool day) or to the surrounding environment (e.g., outside body 44 of electric loader 10, for example, a hot summer day). In various embodiments, cover 46 includes a 1 inch to 3 inches diameter inlet port 68 for receiving forced-air into electric motor 16, specifically between 1.5 inches and 2.5 inches, and more specifically, 1.75 inches to 2.25 inches. In some embodiments, the forced-air is controlled by the processor and uses a variac or variable voltage AC power supply.

FIG. 9 shows electric motor 16 with rotor 50, coils 52, stator 54, and gaps 62. FIG. 10 is an electric motor-hub assembly showing a filter for forced-air venting, according to an exemplary embodiment. FIG. 9 shows an axial bore 53, through which axle 55 (FIG. 24 ) of electric motor 16 couples to gear reducer 36 and wheel 14.

FIG. 11 shows a fixed hub 34 on an attachment plate 35. Attachment plate 35 provides fixed connection points for attaching or coupling drive gear reducer 36 (e.g., the planetary gear system shown in FIG. 8 ) to a side body 44 of electric loader 10. FIG. 11 also includes axial bore 53 in a center that receives axle 55 (FIG. 24 ) of electric motor 16. FIG. 12 shows body 44 of electric loader 10 with four independent electric motor-hub assemblies 56 for independently driving tracks 12 or wheels 14 at each electric motor-hub assembly 56. For example, a single electric motor 16 powers a single track 12 on each side of body 44 with one or more followers or unpowered pivot locations. Alternatively, two or more electric motors 16 could be coupled to a single track 12 and configured to operate dependently, such that each electric motor 16 provides the same torque, speed, and/or power to each track 12. As shown in FIG. 11 , each electric motor-hub assembly 56 independently powers each wheel 14 of electric loader 10.

FIGS. 13 to 17 show various stages of the coupling of electric motor-hub assembly 56 to side of body 44. Specifically, FIG. 13 shows a side view of a gear reducer 36 extending from the side of body 44. Drive gear reducer 36 powers a rotating hub 38 of a track 12 or wheel 14. FIG. 14 is a side view of an electric loader 10 that includes a receiving port 70 for receiving electric motor-hub assembly 56 shown in FIG. 8 and also shows a control port 72 for either a general processor and/or a local processor to control one or more electric motors 16 of electric loader 10. For example, a local processor is assigned to each electric motor 16.

FIG. 15 is a view of electric motor-hub assembly 56 being coupled to receiving port 70 of electric loader 10 or loader. FIG. 16 shows the following step of the installation shown in FIG. 15 . Specifically, FIG. 16 shows how fixed hub 34 attaches to body 44 of electric loader 10 to support an installed electric motor-hub assembly 56 and power a wheel 14. For example, the central control port 72 is used to couple electric motor-hub assembly 56 before the processor and/or other electrical connections are made in control port 72. FIG. 17 is a side view of electric loader 10 with an installed front and rear electric motor-hub assemblies 56. A central control port 72 connects each electric motor 16 to the central processor and/or power source or battery panel 22.

FIG. 18 is an isolated perspective view of a graphical user interface or a display 74 for an operator to interface with the processor and/or a control panel or controller 40. FIG. 19 shows display 74 inside cab 66 of electric loader 10. In various embodiments, display 74 is a system on a chip (SOC) display 74 that display 74 a parking brake, warning signals, limits the travel of loader arm 26 or arm, shows RPM of one or more electric motors, and/or other system information feedback.

FIGS. 20 and 21 show the attachment or coupling of wheels 14 to the electric motor-hub assembly 56. Specifically, rotating power hubs 38 couple to standard tracks 12 or wheels 14 to drive and control electric loader 10. FIG. 20 shows electric loader 10 with four electric motor-hub assemblies 56 attached or coupled independently at four-wheel 14 locations. FIG. 21 shows electric loader 10 with four installed wheels 14 at each electric motor-hub assembly 56.

In some embodiments, a dedicated electric motor 16 is used to drive a lift arm assembly or loader arm 26 and/or other accessories or auxiliary units 76. FIG. 22 shows electric motor 16 coupled to a hydraulic assembly or hydraulic 78 that powers a loader arm 26 and/or one or more hydraulic auxiliary units 76. For example, electric motor 16 powers a hydraulic unit to power loader arm 26 and includes additional auxiliary units 76 to power attachments, such as but not limited to a snow-blower, a lawnmower, a wood chipper, a grapple bucket, a pallet fork, a rake, a log splitter, a saw, a bucket, and/or other hydraulic attachments that enhance the functionality of the electric loader 10. In some embodiments, dedicated electric motor 16 may power other systems, such as an air conditioner. Additional auxiliary systems may be hydraulic or convert electric power into mechanical energy.

FIG. 23 is a front perspective view of the electric motor hydraulic drive assembly shown in FIG. 22 . A controller 40 is shown for electric motor 16 coupled to loader arm 26 and hydraulic auxiliary units 76 and/or for electric motor-hub assembly 56. As shown in FIG. 22 , electric motor-hub assembly 56 includes a motor mount for a second electric motor-hub assembly 56 located close to dedicated electric motor 16 and coupled to hydraulic auxiliary units 76 and/or loader arm 26. FIG. 23 shows a more isolated view of the dedicated electric motor 16. Also shown are ducting for forced-air cooling of dedicated electric motor 16.

FIG. 24 is a cross-sectional view of an electric motor 16 to show cover 46 and/or housing that vents forced-air through electric motor 16 and cools rotor 50, stator 54, and coils 52.

FIGS. 25 to 33 show a central forced-air system 60 that has a dedicated electric motor 16 coupled to a squirrel fan 80 to force air through ducts 48 extending to each electric motor-hub assembly 56. FIGS. 26-28 show perspective views of central forced-air system 60. FIG. 29 shows another embodiment of a central forced-air system 60 that includes electric motor 16 coupled to fan 80 that forces air through ducts 48 leading to inlet port 68 on cover 46 of each electric motor-hub assembly 56. FIG. 30 shows a bottom view of central forced-air system 60 and FIG. 31 shows a top view of central forced-air system 60. FIGS. 32 and 33 are side perspective views of central forced-air system 60 with a chain-case 42 removed (FIG. 32 ) and with the chain-case 42 installed (FIG. 33 ).

FIG. 34 shows a forced-air cooling duct 48 coupled to cover 46 of electric motor 16 of FIG. 24 . Cooling duct 48 forces air through gaps 62 between wound coils 52 of rotor 50, stator 54, and other areas of motor 16.

FIG. 35 shows porting holes 82 for venting electric motor 16. Electric motor 16 may be disposed in chain-case 42 of a conventional diesel design. As shown in FIG. 35 , a diesel engine loader includes a chain-case 42 that receives torque/speed from the diesel engine to drive wheels 14. In the illustrated design, electric motors 16 are located in this area and release heat generated by electric motor 16 into this space. Chain-case 42 can be retrofitted to release this heat to an interior of cab 66 or out to the surrounding environment. Similarly, electric motor-hub assembly 56 may be retrofitted more internal to chain-case 42, such that electric motor 16 is inside cab 66 and drive gear reducer 36 extends into chain-case 42. In this configuration, powered rotating hub 38 extends at or near a side of body 44, such that wheels 14 are located adjacent to body 44, and the electric motor-hub assembly is installed substantially within body 44.

FIG. 36 shows a squirrel fan 80 for a central forced-air venting system 60 that feeds cooling ducts 48 coupled to each electric motor 16. For example, a single fan 80 receives filtered, cleaned, and/or cooled air from a supply source (e.g., dehumidified, particulate-free, and/or air-conditioned air). Fan 80 circulates forced-air through cooling ducts 48 leading to electric motors 16. Electric motors 16 direct the forced-air through gaps 62 in the rotor 50, stator 54, and/or other areas of electric motor 16 and exhaust the air outside electric motor 16. For example, chain-case 42 inside or outside cab 66, or in a user-controlled fashion such that an operator can direct the exhaust of the heated air (e.g., to heat or cool cab 66).

FIGS. 37 and 38 are perspective back views of a battery panel 22 accessed by opening backdoor 20 of electric loader 10. FIG. 37 shows battery panel 22 in an upright or locked position. In this position, battery panel 22 serves as a counter-weight or ballast for the load applied at a front end (e.g., a bucket auxiliary unit 76 of electric loader 10). Similarly, FIG. 38 shows battery panel 22 rotated to an unlocked or open position to provide access to an internal cavity 84 of cab 66.

FIGS. 39 and 40 show the interconnection between battery panel 22 and controller 40. Specifically, battery panel 22 includes wired connections 86 between power cells 24 (e.g., individual batteries). Wired connections 86 are located on an interior side of battery panel 22, e.g., adjacent the internal cavity 84, such that the wired connections 86 are not visible to an operator. The wires 88 couple to a controller 40 adjacent individual electric motors 16. For example, each electric motor 16 has a controller 40, fuse 90, heat sink plate 92, positive and negative terminals 93 (FIG. 17 ). The central processor receives signals from each motor controller 40 and transmitters 94 and/or receivers 96 from one or more sensors 30 related to traction, slip, weight, and/or load at each electric motor 16 and/or wheel 14. In other words, sensor 30 data is communicated to the central processor and provides feedback to an operator, automates operation of electric loader, display 74 warnings, and/or enhance independent traction and/or drive of each wheel 14 independently. FIG. 39 shows a top view of the inside of battery panel 22 that includes wires 88 interconnecting battery cells 24 to electric motors 16 and/or controllers 40 to provide individualized power for each electric motor-hub assembly 56. FIG. 40 shows individual motor controllers 40 or control panels coupled to each electric motor 16 to control and/or regulate electric energy/power delivered to electric motor 16.

FIGS. 41 to 44 show isometric top (FIGS. 43 and 44 ) and back (FIGS. 41 and 42 ) views of electric loader 10 with backdoor 20 open to show battery panel 22 in an upright or locked position (FIGS. 41 and 43 ) and rotated into a lowered or unlocked position (FIGS. 42 and 44 ) to provide access to internal cavity 84 of cab 66. FIG. 45 is a top isometric view of electric loader 10 with a closed backdoor 20 to show the operating configuration of electric loader 10. In this configuration, the installed battery panel 22 is in an upright or locked position and provides a counterweight to front end (e.g., bucket) of loader arm 26 and/or electric loader 10.

FIGS. 46 to 49 show isolated views of a rotating battery panel 22 located within a frame 98 that can insert into electric loader arm 26. In some embodiments, frame 98 and/or battery panel 22 is removed from electric loader 10 or added to an existing (e.g., diesel) frame to retrofit a power supply to an existing design. FIG. 47 is a top perspective view of an isolated rotating battery panel 22 and frame 98 shown in an upright or locked position. FIG. 48 is a top perspective view of an isolated rotated battery panel 22 and frame shown in an unlocked, lowered, or open position. FIG. 49 is an isometric view of a backside of battery panel 22 located inside frame 98 in a locked upright position.

FIG. 50 is an isolated view of battery panel 22 showing various control knobs and charging ports 100 to charge individual battery cells 24 and/or remove battery cells 24. For example, each battery cell 24 is locked in a box 102 with a locking mechanism 104. Locking mechanism 104 can be released to replace or repair an individual battery cell 24. Similarly, a charging port 100 is located in each box 102 to couple individual charges to each battery cell 24. For example, each battery cell 24 can be charged independently and/or collectively at charging ports 100. For example, a single charging port 100 is used to charge all battery cells 24 in battery panel 22, or individual charging ports 100 isolate a single battery cell 24 for independent recharging.

FIG. 51 is an isolated view of the battery panel 22 from inside cab 66 and shows a plurality of storing locations or boxes 102 for a plurality of battery cells 24. In some embodiments, each battery cell 24 is locked with a locking mechanism 104 inside a box 102 of battery panel 22. FIG. 52 is a side perspective view of battery panel 22 rotated into an unlocked position to provide access to internal cavity 84 of frame 98 and/or cab 66. In this configuration, each battery cell 24 is locked inside battery panel 22, such that all battery cells 24 remain locked within battery panel 22 when the panel is rotated away from frame 98. In some embodiments, the kinematics of the rotation of battery panel 22 assists in the rotation from a locked to an unlocked position. For example, battery panel 22 is spring-loaded to return the panel to the locked position (e.g., closed).

FIG. 53 is a side perspective view of an empty battery panel 22 in the locked or upright position. As shown, empty battery panel 22 does not have a locking mechanism 104 and is shown without installed battery cells 24. In contrast, FIG. 54 shows battery panel 22 with installed battery cells 24, locking mechanisms 104 for each box 102, and a charging port 100 for each individual battery cell 24. FIGS. 55 and 57 show empty battery trays without locking mechanisms 104 or battery cells 24. FIG. 56 shows a battery cell 24 and an individual battery box 102 that secures battery cell 24 in battery panel 22.

FIGS. 58 and 59 are front views of battery panel 22 in a rotated or unlocked position (FIG. 58 ) and an upright or locked position (FIG. 59 ) within the frame. FIG. 60 is an isometric front view of battery panel 22 within frame 98. In this view, a backside of battery panel 22 is shown that includes wires 88 and wired coupling of battery cells 24. As shown in FIGS. 37-39 frame 98 and battery panel 22 is inserted into body 44 of electric loader 10 and may be used to retrofit an existing loader with electrical power, e.g., for converting a conventional loader with electrical power at individual electric motors 16 at each wheel 14 or rotating hub 38.

It should be understood that the figures illustrate the exemplary embodiments in detail, and it should be understood that the present application is not limited to the details or methodology set forth in the description or illustrated in the figures. It should also be understood that the terminology is for the purpose of description only and should not be regarded as limiting.

Further modifications and alternative embodiments of various aspects of the invention will be apparent to those skilled in the art in view of this description. Accordingly, this description is to be construed as illustrative only. The construction and arrangements, shown in the various exemplary embodiments, are illustrative only. Although only a few embodiments have been described in detail in this disclosure, many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter described herein. Some elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. The order or sequence of any process, logical algorithm, or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes, and omissions may also be made in the design, operating conditions, and arrangement of the various exemplary embodiments without departing from the scope of the present invention.

For purposes of this disclosure, the term “coupled” means the joining of two components directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional member being attached to one another. Such joining may be permanent in nature or alternatively may be removable or releasable in nature.

While the current application recites particular combinations of features in the claims appended hereto, various embodiments of the invention relate to any combination of any of the features described herein whether or not such combination is currently claimed, and any such combination of features may be claimed in this or future applications. Any of the features, elements, or components of any of the exemplary embodiments discussed above may be used alone or in combination with any of the features, elements, or components of any of the other embodiments discussed above.

In various exemplary embodiments, the relative dimensions, including angles, lengths, and radii, as shown in the Figures, are to scale. Actual measurements of the Figures will disclose relative dimensions, angles, and proportions of the various exemplary embodiments. Various exemplary embodiments extend to various ranges around the absolute and relative dimensions, angles, and proportions that may be determined from the Figures. Various exemplary embodiments include any combination of one or more relative dimensions or angles that may be determined from the Figures. Further, actual dimensions not expressly set out in this description can be determined by using the ratios of dimensions measured in the Figures in combination with the express dimensions set out in this description. In addition, in various embodiments, the present disclosure extends to a variety of ranges (e.g., plus or minus 30%, 20%, or 10%) around any of the absolute or relative dimensions disclosed herein or determinable from the Figures. 

1. An electric loader, comprising: a first electric wheel assembly having a first wheel with a first hub, a first motor, and a first gear reducer, wherein the first motor is coupled to the first hub by the first gear reducer and the first motor is coupled to a central processor; a second electric wheel assembly having a second wheel with a second hub, a second motor, and a second gear reducer, wherein the second motor is coupled to the second hub by the second gear reducer and the second motor is coupled to the central processor; a third electric motor coupled to a hydraulic pump; and a hydraulic lift coupled to the hydraulic pump, wherein the processor is configured to control the first electric wheel assembly and the second electric wheel assembly independently.
 2. (canceled)
 3. (canceled)
 4. The electric loader of claim 1, further comprising first and second lever brakes coupled to first and second output axles of the first and second electric motors, respectively.
 5. (canceled)
 6. The electric loader of claim 1, further comprising a hydraulic an accessory coupled to the hydraulic pump, the hydraulic accessory being powered by the hydraulic pump.
 7. The electric loader of claim 1, further comprising a fourth electric motor coupled to a fourth wheel and a fifth electric motor coupled to a fifth external drive.
 8. (canceled)
 9. The electric loader of claim 1, wherein the first motor includes a first cover, a first stator, and a first rotor, and the second motor includes a second cover, a second stator, and a second rotor, wherein the first motor includes a first gap between the first stator and the first rotor and the second motor includes a second gap between the second stator and the second rotor.
 10. The electric loader of claim 9, further comprising a central forced-air system for forcing air through the first gap and the second gap, the central forced-air system including a filter, a fan, an air conditioner to remove heat and humidity from the air, and a plurality of ducts coupling the fan to the first cover and the second cover.
 11. An electric loader, comprising: a first electric motor having a first stator, a first rotor, first coil windings, and a first axle coupled to a first planetary gear system, the planetary gear system coupled to, and positioned at least partially inside of, a first rotary hub of a first wheel; and a second electric motor having a second stator, a second rotor, second coil windings, and a second axle coupled to a second planetary gear system, the second planetary gear system coupled to, and positioned at least partially inside of, a second rotary hub of a second wheel.
 12. The electric loader of claim 22, further comprising a plurality of battery cells in the battery panel, the battery cells being locked within the battery panel with a locking mechanism, and wherein the locking mechanism includes a port for isolated charging of each battery cell.
 13. The electric loader of claim 11, further comprising a lever brake coupled to the first and the second axles of the first and second electric motors.
 14. The electric loader of claim 11, further comprising a cover with an input port and a plurality of fins, the input port configured to receive forced-air that is cooled and filtered into gaps in the first and second rotor and the first and second stator, and wherein the plurality of fins are configured to radiate heat away from the cover.
 15. (canceled)
 16. (canceled)
 17. (canceled)
 18. A retrofit loader, comprising: a first electric motor coupled to a first gear reducer, the first electric motor coupled to a first external drive; a second electric motor coupled to a second gear reducer, the first electric motor coupled to a second external drive; a first fixed hub and a first rotary hub each coupled to the first electric motor, the first fixed hub coupled to, and received within, a first receiving port of a body of the retrofit loader and the first rotary hub coupled to the first external drive; a second fixed hub and a second rotary hub each coupled to the second electric motor, the second fixed hub coupled to, and received within, a second receiving port of the body of the retrofit loader and the second rotary hub coupled to the second external drive; and an auxiliary electric motor coupled to a hydraulic pump, wherein each of the first, the second, and the auxiliary electric motors are driven independently.
 19. The retrofit loader of claim 18, further comprising an attachment hydraulically coupled to the hydraulic pump, a central fan, a filter, a plurality of ducts that enter a first input port of a first cover of the first electric motor and a second input port of a second cover of the second electric motor, and an air conditioner to cool, clean, and force air through the plurality of ducts.
 20. The retrofit loader of claim 18, further comprising a battery panel that houses a plurality of battery cells, the battery panel pivotably coupled to a frame of the retrofit loader that pivots between an upright locked position and a lowered unlocked position; and a locking mechanism in the battery panel for each battery cell, wherein the locking mechanism comprises a bolt lock that locks the battery cell in the battery panel, and wherein the locking mechanism further comprises a charging port for each battery cell.
 21. The electric loader of claim 4, wherein the first and second lever brakes couple to the first output shaft and the second output shaft respectively, and wherein the first and second lever brakes use torque generated by the first and second electric motors to lock the first and second external drives.
 22. The electric loader of claim 11, further comprising a battery panel pivotably coupled to a frame, the battery panel electrically coupled to the first and second electric motors and rotating from an upright locked position to a lowered locked position.
 23. The retrofit loader of claim 18, wherein the first external drive and the second external drive are wheels.
 24. The retrofit loader of claim 18, wherein the first external drive and the second external drive are tracks.
 25. The retrofit loader of claim 18, wherein the first electric motor and the second electric motor are positioned within the body and the first gear reducer and the second gear reducer extend outside of the body.
 26. The retrofit loader of claim 18, wherein the body further comprises a control port that receives a processor designed to control the first electric motor and the second electric motor.
 27. The retrofit loader of claim 26, wherein the processor includes a plurality of traction modes that are activated based on one or more sensors configured to detect slipping of one or both of the first external drive and the second external drive. 